Adjustable headwear

ABSTRACT

There is provided headwear comprising, a crown defining an opening for receiving a head of a wearer, an actuator configured to receive an application of a force, and a force transmission member coupled to the actuator. The actuator is configured to effect, when a head is received within the crown, and relative to the head received within the crown, a change in disposition of the force transmission member to any one of a plurality of conditions in response to an application of force to the actuator, wherein, in at least one of the plurality of conditions, an operative surface of the force transmission member is bearing against a surface fraction of the head received within the crown. The surface fraction of the head extends substantially continuously from: a point within a first distance of about two inches from a first temple reference plane defined by one of the temples of one side of the head and rearwardly towards the rear of the head, about the rear of the head and towards the other side of the head, and to a point within a second distance of about two inches from a second temple reference plane defined by the other one of the temples of the other side of the head, wherein the first distance is measured along an axis normal to the first reference plane and wherein the second distance is measured along an axis normal to the second reference plane, hi each one of the at least one of the plurality of conditions where the operative surface is bearing against a surface fraction of a head received within the crown, the bearing of the operative surface against the surface fraction of the head is limited to a surface fraction disposed rearwardly of the forehead.

FIELD OF INVENTION

This invention relates to headwear and, in particular, to adjustableheadwear.

BACKGROUND OF THE INVENTION

Head size varies from person to person. In supplying headwear to themarketplace, headwear manufacturers must make headwear available toaccommodate persons of different head sizes. In this respect, headwearmanufacturers provide adjustable headwear which is suitable for use bywide segments of the headwear wearing population.

U.S. Pat. No. 5,331,687 issued to Kronenberger discloses a sizeadjustable headwear piece includes an actuator with a dial which ismanually rotatable to effect a change in size of the opening of thecrown. Amongst other things, the actuator of Kronenberger is disposedwithin the sweatband, which renders manufacture of the headwear piecedifficult.

U.S. Pat. No. 5,433,648 issued to Frydman discloses a rotatable closuredevice for hats which includes a spool for drawing in and taking uptwine. The twine is coupled to the cap base, such that the drawing inaction causes the cap base to decrease in size in order to accommodatesmaller head sizes. Amongst other things, the twine of the device inFrydman tends to effect an undesirable degree of bunching fabric as thetwine is drawn in and taken up by the spool.

SUMMARY OF THE INVENTION

In one aspect, there is provided headwear comprising: a crown definingan opening for receiving a head of a wearer; an actuator configured toreceive an application of a force; a force transmission member coupledto the actuator; such that the actuator is configured to effect, when ahead is received within the crown, and relative to the head receivedwithin the crown, a change in disposition of the force transmissionmember to any one of a plurality of conditions in response to anapplication of force to the actuator, wherein, in at least one of theplurality of conditions, an operative surface of the force transmissionmember is bearing against a surface fraction of the head received withinthe crown; wherein the surface fraction of the head extendssubstantially continuously from: a point within a first distance ofabout 5.08 centimetres from a first temple reference plane defined byone of the temples of one side of the head and rearwardly towards therear of the head, about the rear of the head and towards the other sideof the head, and to a point within a second distance of about 5.08centimetres from a second temple reference plane defined by the otherone of the temples of the other side of the head, wherein the firstdistance is measured along an axis normal to the first reference planeand wherein the second distance is measured along an axis normal to thesecond reference plane, and wherein in each one of the at least one ofthe plurality of conditions where the operative surface is bearingagainst a surface fraction of a head received within the crown, thebearing of the operative surface against the surface fraction of thehead is limited to a surface fraction disposed rearwardly of theforehead.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion and a crowncoupling portion, wherein the actuator coupling portion is coupled tothe force transmission coupling unit of the actuator, and wherein thecrown coupling portion is attached to the force transmission membercoupling portion, such that the operative force transmission membersection extends from: the actuator coupling unit and rearwardly towardsthe rear of the crown, about the rear of the crown and towards the otherside of the crown, and to the force transmission member couplingportion; and wherein the force transmission member coupling unit of theactuator is disposed at one side of the headwear, and between a frontand a rear of the headwear; and wherein the force transmission membercoupling portion is disposed at a side of the headwear which is oppositeto the side on which the operative portion of the actuator is disposed,and between a front and a rear of the headwear; such that the actuatoris configured to effect, when a head is received within the crown, anapplication of a force to the operative force transmission membersection, such that the operative force transmission member sectionchanges its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown.

In a further aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured to receive an application of a force and including a forcetransmission coupling unit; a force transmission member couplingportion; a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion and a crowncoupling portion, wherein the actuator coupling portion is coupled tothe force transmission coupling unit of the actuator, and wherein thecrown coupling portion is attached to the force transmission membercoupling portion; and wherein the distance from the most rearward edgeof the actuator coupling unit to a first temple reference plane, definedby one of the temples of one side of the head, is less than about 5.08centimetres, wherein the distance is measured along a longitudinal axisof the force transmission member; and wherein the distance from the mostrearward edge of the force transmission coupling portion to a secondtemple reference plane, defined by the other one of the temples, is lessthan about 5.08 centimetres, wherein the distance is measured along alongitudinal axis of the force transmission member; such that theactuator is configured to effect, when a head is received within thecrown, and relative to the head received within the crown, a change indisposition of the force transmission member to any one of a pluralityof conditions in response to an application of force to the actuator,wherein, in at least one of the plurality of conditions, an operativesurface of the force transmission member is bearing against a surfacefraction of the head received within the crown.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion and a crowncoupling portion, and wherein the actuator coupling portion is coupledto the force transmission coupling unit of the actuator, and wherein thecrown coupling portion is coupled to the force transmission membercoupling portion, and wherein the force transmission member includes arelatively rigid portion and a relatively resilient portion; such that,the actuator is configured to effect, when a head is received within thecrown, an application of a force to the operative force transmissionmember section, such that the operative force transmission membersection changes its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; and a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion and a crowncoupling portion, and wherein the actuator coupling portion is coupledto the force transmission coupling unit of the actuator, and wherein thecrown coupling portion is coupled to the force transmission membercoupling portion, and wherein the force transmission member includes arelatively harder portion and a relatively softer portion such that, theactuator is configured to effect, when a head is received within thecrown, an application of a force to the operative force transmissionmember section, such that the operative force transmission membersection changes its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; and a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion and a crowncoupling portion, and wherein the actuator coupling portion is coupledto the force transmission coupling unit of the actuator, and wherein thecrown coupling portion is coupled to the force transmission membercoupling portion, and wherein the force transmission member includes arelatively harder portion and a relatively softer portion; such that,the actuator is configured to effect, when a head is received within thecrown, an application of a force to the operative force transmissionmember section, such that the operative force transmission membersection changes its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; and a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion and a crowncoupling portion, and wherein the actuator coupling portion is coupledto the force transmission coupling unit of the actuator, and wherein thecrown coupling portion is coupled to the force transmission membercoupling portion, and wherein the force transmission member includes arelatively harder portion and a relatively softer portion; such that,the actuator is configured to effect, when a head is received within thecrown, an application of a force to the operative force transmissionmember section, such that the operative force transmission membersection changes its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown.

In a further aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer, and including: twoadjacent panels attached to one another along respective and abuttingsides to define a seam, seam tape disposed across the seam and coupledto each one of the two adjacent panels; an actuator configured forreceiving an application of force, and including a force transmissionmember coupling unit; a force transmission member including an operativeforce transmission member section, wherein the operative forcetransmission member section includes an actuator coupling portion and acrown coupling portion, wherein the actuator coupling portion is coupledto the force transmission coupling unit of the actuator, and wherein thecrown coupling portion is attached to the seam tape; such that, theactuator is configured to effect, when a head is received within thecrown, an application of a force to the operative force transmissionmember section, such that the operative force transmission membersection changes its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion coupled to theforce transmission coupling unit of the actuator; wherein the ratio of:(i) the operative surface area of an operative surface of at least afraction of the operative force transmission member section, to (ii) thelength of the at least a fraction, is from about 6.3 mm²/mm to about13.6 mm²/mm, wherein the at least a fraction includes at least oneportion of the operative force transmission member section, and whereineach one of the at least one portion includes a respective operativesurface portion and a respective portion length, such that, where the atleast one portion is one portion of the operative force transmissionmember section, the operative surface fraction is defined by therespective operative surface portion of the one portion and the lengthof the at least a fraction is defined by the respective portion lengthof the one portion, and where the at least one portion is at least twoportions of the operative force transmission member, the operativesurface fraction is defined by the sum of the respective operativesurface portions of the at least two portions and the length of the atleast a fraction is defined by the sum of the respective portion lengthsof the at least two portions; such that, the actuator is configured toeffect, when a head is received within the crown, application of a forceto the operative force transmission member section, such that theoperative force transmission member section changes its conditionrelative to a surface fraction of the head received within the crown toany one of a plurality of conditions in response to an application offorce to the actuator, wherein, in at least one of the plurality ofconditions, an operative surface of the operative force transmissionmember section is bearing against a surface fraction of the headreceived within the crown, and wherein the operative surface includesthe operative surface fraction.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion coupled to theforce transmission coupling unit of the actuator; a guide system forguiding movement of the force transmission member; wherein the minimumwidth of at least a fraction of the operative force transmission membersection is at least about 13 millimetres, such that the minimum widthco-operates with the guide system during the forward movement of theforce transmission member relative to the actuator such that thevertical displacement of the operative force transmission member sectionis limited during the movement of the force transmission member relativeto the actuator; and wherein the ratio of: (i) the operative surfacearea of an operative surface of at least a fraction of the operativeforce transmission member section, to (ii) the length of the at least afraction, is less than about 13.6 mm²/mm; and wherein the at least afraction includes at least one portion of the operative forcetransmission member section, and wherein each one of the at least oneportion includes a respective operative surface portion and a respectiveportion length, such that, where the at least one portion is one portionof the operative force transmission member section, the operativesurface fraction is defined by the respective operative surface portionof the one portion and the length of the at least a fraction is definedby the respective portion length of the one portion, and where the atleast one portion is at least two portions of the operative forcetransmission member, the operative surface fraction is defined by thesum of the respective operative surface portions of the at least twoportions and the length of the at least a fraction is defined by the sumof the respective portion lengths of the at least two portions andwherein the length of the at least a fraction is defined as a sum of theportion lengths; such that, the actuator is configured to effect, when ahead is received within the crown, application of a force to theoperative force transmission member section, such that the operativeforce transmission member section changes its condition relative to asurface fraction of a head received within the crown to any one of aplurality of conditions in response to an application of force to theactuator, wherein, in at least one of the plurality of conditions, anoperative surface of the operative force transmission member section isbearing against a surface fraction of the head received within thecrown, wherein the operative surface includes the operative surfacefraction; and wherein, while changing a condition of its dispositionrelative to a head received within the crown in response to theapplication of force to being effected by the actuator, the forcetransmission member moves forwardly relative to the actuator.

In another aspect, there is provided headwear comprising: a crowndefining an opening for receiving a head of a wearer; an actuatorconfigured for receiving an application of force, and including a forcetransmission member coupling unit; a force transmission member couplingportion; a force transmission member including an operative forcetransmission member section, wherein the operative force transmissionmember section includes an actuator coupling portion coupled to theforce transmission coupling unit of the actuator; such that the actuatoris configured to effect, when a head is received within the crown,application of a force to the operative force transmission membersection, such that the operative force transmission member sectionchanges its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown, and wherein, whilechanging a condition of its disposition relative to a head receivedwithin the crown in response to the application of force being effectedby the actuator, the force transmission member moves forwardly relativeto the actuator; and a guard configured for disposition between thecrown and the force transmission member as the force transmission membermoves forwardly relative to the actuator while the actuator effectsapplication of the force to the operative force transmission membersection.

In a further aspect, there is provided a method of manufacturingheadwear of a predetermined size, the headwear including a crowndefining an opening for receiving a head of a wearer, an actuatorconfigured for receiving an application of a force, and a forcetransmission member configured for disposition relative to a headreceived within the crown, wherein the force transmission member iscoupled to the actuator, such that the actuator is configured to effect,when a head is received within the crown, and relative to the headreceived within the crown, a change in disposition of the forcetransmission member to any one of a plurality of conditions in responseto an application of force to the actuator, and wherein in at least oneof the plurality of conditions, an operative surface of the forcetransmission member is bearing against a surface fraction of the headreceived within the crown; comprising: providing a longitudinallyextending force transmission member portion pre-form including aplurality of cutting indications, wherein each one of the plurality ofcutting indications corresponds to a pre-determined location for cuttingthe pre-form to provide a modified pre-form suitable for use as at leasta portion of the force transmission member; cutting the pre-form at apredetermined cutting indication corresponding to the pre-determinedsize of headwear being manufactured.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side elevation view of one side of an embodiment of theadjustable headwear while the headwear is being worn by a person;

FIG. 2 is a side elevation view of a second side of the adjustableheadwear of FIG. 1 while the headwear is being worn by a person, whereinthe second side is opposite to the side illustrated in FIG. 1;

FIG. 3 is a front elevation view of the adjustable headwear of FIG. 1while the headwear is being worn by a person;

FIG. 4 is a top plan view of the adjustable headwear of FIG. 1;

FIG. 5 is a top plan view of the adjustable headwear of FIG. 1,illustrating the force transmission member, in hidden lines, in twoconditions;

FIG. 5A is a top plan view of the adjustable headwear of FIG. 1,illustrating the force transmission member, in hidden lines, in twoconditions relative to a head received within the crown (the head alsobeing illustrated in hidden lines)

FIG. 5B is a top plan view of another embodiment of the adjustableheadwear, substantially identical with the adjustable headwear of FIG.1, with the exception that this embodiment includes a guard disposedbetween the force transmission member and the crown wherein the forcetransmission member is illustrated in hidden lines in two conditions andthe guard is also illustrated in hidden lines;

FIG. 6 is a bottom perspective view of the adjustable headwear of FIG.1, partly in fragment, illustrating the disposition of the forcetransmission member relative to the crown;

FIG. 7 is a front perspective view of a force transmission member of theadjustable headwear illustrated in FIG. 1;

FIG. 7A is a front perspective view of an alternative embodiment of aforce transmission member of the adjustable headwear illustrated in FIG.1;

FIG. 7B is a fragmentary top plan view of one end of the forcetransmission member illustrated in FIG. 7A;

FIG. 8 is a front perspective view of a strap portion of a pre-form ofthe force transmission member illustrated in FIG. 7;

FIG. 8A is a front perspective view of the end of the force transmissionmember of FIG. 7 including the strap portion;

FIG. 9 is a front plan view of another embodiment of a forcetransmission member of the adjustable headwear of FIG. 1, illustratingthe force transmission member embodiment disposed within a guide memberand coupled to an actuator;

FIG. 10 is an exploded fragmentary top perspective view of a portion ofa guide member and an actuator of the adjustable headwear of FIG. 1,illustrating the locations of the guide member to which the actuator isstitched;

FIG. 11 is a fragmentary top perspective view of a portion of a guidemember and an actuator of FIG. 10, illustrating the actuator after ithas been stitched to the guide member;

FIG. 12 is a fragmentary bottom perspective view of the adjustableheadwear of FIG. 1 in a partly finished condition and as it is beingassembled;

FIG. 13 is a bottom perspective view of the adjustable headwear of FIG.1 in a further partly finished condition and as it is being assembled,and after the force transmission member has been coupled to the crownand to the actuator;

FIG. 14 is a fragmentary bottom perspective view of an interior portionof the adjustable headwear of FIG. 1 in a partly finished condition andas it is being assembled, illustrating the force transmission memberbeing fed through a slit provided in the guide member to facilitatecoupling of the force transmission member to the actuator;

FIG. 14A is a fragmentary bottom perspective view of an interior portionof the adjustable headwear illustrated in FIG. 5B in a partly finishedcondition and as it is being assembled, illustrating the forcetransmission member being fed through a slit provided in the guidemember to facilitate coupling of the force transmission member to theactuator;

FIG. 15 is a fragmentary elevation view of an interior portion of theadjustable headwear of FIG. 1 in a partially finished condition and asit is being assembled, illustrating the force transmission membercoupled to the actuator and before the guide member is rotated to effectinsertion of the actuator through an aperture of the crown;

FIG. 16 is a fragmentary perspective view of an exterior portion of theadjustable headwear of FIG. 1 in a partially finished condition and asit is being assembled and before the guide member is rotated to effectinsertion of the actuator through the aperture of the crown;

FIG. 17 is a fragmentary perspective view of an exterior portion of theadjustable headwear of FIG. 1 after the actuator has been insertedthrough an aperture of the crown;

FIG. 18 illustrates a set of components for implementing a cam assemblyand strap based closure system using a spiral from a perspective view,in accordance with some embodiments of the inventions.

FIGS. 19A, 19B, and 19C illustrate the cam assembly and strap basedclosure system of FIG. 18 from a side, top, and bottom view, inaccordance with some embodiments of the inventions.

FIGS. 20A, 20B, 20C, and 20D illustrate the cam of FIG. 18 from a top,bottom, and perspective views, in accordance with some embodiments ofthe inventions.

FIGS. 21A, 21B, and 21C illustrate the track insert of FIG. 18 from aperspective, top, and side view, in accordance with some embodiments ofthe inventions.

FIGS. 22A, 22B, 22C, and 22D illustrate the housing of FIG. 18 from aperspective, side, top, and bottom view, in accordance with someembodiments of the inventions.

FIG. 23 illustrates the knob of FIG. 18 from a perspective view, inaccordance with some embodiments of the inventions.

FIG. 24 illustrates the overmold of the knob of FIG. 23 from a bottomview, in accordance with some embodiments of the inventions.

FIGS. 25A and 25B illustrate the undermold of the knob of FIG. 23 from aperspective and bottom view, in accordance with some embodiments of theinventions.

FIGS. 26A, 26B, 26C, 26D, 26E, and 26F illustrate a flowchart of theengagement of the strap pins of FIG. 7 with the cam spirals of FIG. 20Cwhen the strap of FIG. 18 is being driven into the cam assembly of FIG.18, in accordance with some embodiments of the inventions.

FIGS. 27A, 27B, 27C, 27D, 27E, and 27F illustrate a flowchart of theengagement of the strap pins of FIG. 7 with the cam spirals of FIG. 20Cwhen the strap of FIG. 18 is being driven out of the cam assembly ofFIG. 18, in accordance with some embodiments of the inventions;

FIG. 28A is a front plan view of another embodiment of a forcetransmission number of the adjustable headwear illustrated in FIG. 1;

FIG. 28B is a front plan view of the relatively harder strap portion ofthe force transmission member illustrated in FIG. 28A; and

FIG. 28C is a side elevation view of the relatively harder strap portionof the force transmission member illustrated in FIG. 28A.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Unless otherwise indicated, all numbers expressing quantities ofingredients, properties such as distance, operating conditions, and soforth used in the specification and claims are to be understood as beingmodified in all instances by the term “about.” Accordingly, unlessindicated to the contrary, the numerical parameters set forth in thefollowing specification and attached claims are approximations that mayvary depending upon the desired properties sought to be obtained by thepresent invention. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contain errorsnecessarily resulting from the standard deviation found in theirrespective testing measurements.

Referring to FIGS. 1, 2, 3, 4, 5, 5A, 5B and 6, there is providedheadwear 10 including an adjustment system for accommodating varioushead dimensions. In this respect, there is provided headwear 10 definingan opening 12 for receiving a human head 14, and an adjustment systemfor adjusting the fit of the headwear 10 to the human head 14 receivedthereby.

To assist in understanding the described embodiments, the terms “firsttemple reference plane” and “second temple reference plane” are definedas follows. Referring to FIGS. 1, 2, 3, and 5A, the first templereference plane 16 is a vertical plane in which a vertical axis 20 a ofthe temple 22 a of a side of the head 14 closest to the actuator 38 (seebelow) is disposed, and which is parallel to a vertical plane which istangent to the most forwardly disposed portion of a wearer's forehead24. The second temple reference plane 18 is a vertical plane in which avertical axis 20 b of the temple 22 b at the other side of the head 14is disposed, and which is parallel to a vertical plane which is tangentto the most forwardly disposed portion of a wearer's forehead 24.

The following discussion and associated figures describe the headwear 10as having the form of a baseball cap. The concepts and features of theheadwear 10 may be applied to a wide variety of headwear 10 types.Examples of such headwear 10 types include baseball caps (full-back andopen-back), fedoras, “engineer”-type hats, “ivy”-type hats,“newsboy”-type hats, bucket hats, visors, and knitted hats.

The spatial disposition of certain elements of the headwear 10 aresometimes described relative to a head of a person received within acrown 26 of the headwear 10, or relative to other elements of theheadwear 10, or relative to each other. It is intended to describe suchspatial disposition when the headwear 10 is being worn in its intendedposition relative to the head 14 of a wearer. As well, terms such as“front”, “rear”, “side”, “above”, or “below” are also sometimes used todescribe the disposition of elements of the headwear 10. Such terms areintended to refer to the disposition of the element relative to a head14 of a person wearing the headwear 10, or relative to another elementof the headwear 10, when the headwear 10 is being worn in its intendedposition relative to the head 14 of a wearer. For example, with respectto a baseball cap-type of headwear 10, the baseball cap is intended tobe worn with its visor 30 extending forwardly relative to the forehead,even though the baseball cap may be worn with the visor 30 extendingrearwardly or to one side.

For example, with respect to the headwear 10, the headwear 10 includes acrown 26, and the crown 26 is of a generally hemispherical formconfigured for the covering of a head 14 of a person.

For example, with further respect to the crown 26, the crown 26 includesa plurality of panels 28 (or gores) that are attached together alongrespective and abutting sides. For example, each of the panels 28 ismade from flexible material. Also, for example, the panels 28 may bemade from relatively inflexible material. With respect to the flexiblematerial, for example, the flexible material is textile. For example, asuitable textile is fabric. For example, the flexible material can bemade from a blend of weaveable fibers. For example, the flexiblematerial is 100% wool. For example, the flexible material includes anelastic component, and the elastic component is characterized as beingresilient. For example, the elastic component is spandex which is weavedinto the flexible material. For example, the flexible material includesfrom 0 vol. % to 5 vol. % of elastic component based on the total volumeof the flexible material. For example, the elastic component is disposedsubstantially uniformly throughout the flexible material.

For example, the attachment of the panel 28 is effected by the stitchingtogether abutting sides of the panel 28 to define seams. For example,seam tape 70 may be applied to the interior surface across and joined toabutting panels 28 to reinforce the seams between panels 28. For examplethe seam tape 70 is stitched to each one of a respective one of eachpair of abutting panels 28. For example the seam 70 includes the samematerial as that used for the panels 28. For example, with respect toeach of the panels 28, the thickness of each of the panels is from one(1) millimetre to two (2) millimetres.

For example, with respect to the headwear 10, the headwear 10 furtherincludes a peak 30. The peak 30 is attached to a front portion 32 of thecrown 26 and extends forwardly of the crown 26. In this respect, theheadwear 10 including a peak 30 is configured to be worn on the head 14of a human such that the peak 30 extends forwardly relative to the faceof the human. For example, with respect to the attachment of the peak 30to the crown 26, the peak 30 is attached to the front facing portion ofthe crown 26 by sewing the peak to the front facing crown portion alongand proximate to the bottom edge of the front facing crown portion. Thelower edge of the front facing portion is folded inwardly along thelength of the lower edge. A stiffening or reinforcing tape is then laidover the fold, and the peak 30 is then stitched along and proximate tothe edge formed by the fold.

For example, with respect to the peak 30, the peak 30 includes materialwhich is relatively more rigid than the crown portion to which the peak30 is attached. For example, as is typical with peaks, the relativelymore rigid material is a pre-molded and cut plastic form with a materialsheath pulled over it.

For example, with respect to the crown portion attached along a rearedge 34 of the peak 30, from one side 31 a of the peak 30 to the otherside 31 b of the peak 30, the crown portion includes a material band 36disposed immediately above the peak 30. For example, the material band26 is made from any one of: terry cloth, wicking fabric, cotton, wool,foam, and thick interface material. For example, nanomaterials can beadded as a treatment to these materials.

The adjustment system includes an actuator 38 and a force transmissionmember 40. The force transmission member 40 includes an operativesection 44 including an operative surface configured for bearing againsta surface fraction of a head received within the crown 26.

The actuator 38 is configured to receive an application of a forceeffected by a human hand. For example, the actuator 38 is coupled to thecrown 26. Further details of an embodiment of the actuator 38, and itsrelationship to the force transmission member 40, are set out on below.

Referring to FIGS. 5, 9, and 15, the force transmission member 40 iscoupled to a force transmission member coupling unit 42 of the actuator38. For example, such coupling is a releasable coupling. By virtue ofsuch coupling, the actuator 38 is configured to effect, when a head 14is received within the crown 26, and relative to a head 14 receivedwithin the crown 26, a change in disposition of the force transmissionmember 40 to any one of a plurality of conditions. Referring to FIGS.1,2,3 and 5A, in at least one of the plurality of conditions, theoperative surface of the operative section 44 of the force transmissionmember 40 is bearing against a surface fraction of the head 14 receivedwithin the crown 26, in response to an application of force to theactuator 38. In this respect, the bearing of the operative surface ofthe operative section 44 of the force transmission member 40 against thesurface fraction of the head 14 received within the crown 26 is effectedby an application of force to the actuator 38. For example, by effectingthe bearing of the operative surface of the operative section 44 of theforce transmission member 40 against the surface fraction of the head 14received within the crown 26, the actuator 38 effects tightening of theheadwear 10 relative to the head 14 received within the crown 26, andthereby effects a better fit of the headwear 10 relative to the head 14received within the crown 26. For example, the force transmission member40 is disposed within an interior of the crown 26.

For example, with respect to the effect on the force transmission member40 of applying a force to the actuator 38, while changing a condition ofdisposition relative to a head 14 received within the crown 26 inresponse to the application of force to the actuator 38, the forcetransmission member 40 changes position (or moves) relative to theactuator 38. Each of FIGS. 5, 5A, and 5B illustrate the change incondition of the force transmission member 40 as a force is applied tothe actuator 38. In each case, reference numeral 800 represents theforce transmission member 40 in an original condition, and referencenumeral 900 represents the force transmission member in a new condition,having become repositioned as a result of a force being applied to theactuator 38.

It is understood that bearing of the force transmission member 40against a surface function of a head 14 received within the crown 26does not necessarily require that the force transmission member 40 be indirect contact with the head 14. The bearing of the force transmissionmember 40 effects mounting of the headwear 10 to the head 14 in adesired position (but not necessarily a permanently fixed position, andit is understood that application of relatively minor forces to theheadwear, such as that which may be applied by a human hand, may besufficient to dislodge the headwear from the desired position) relativeto the head.

For example, and referring to FIGS. 5, 5A, 6, and 7, with respect to therelationship between the actuator 38 and the force transmission member40, the operative section 44 of the force transmission member 40includes an actuator coupling portion 46 coupled to the forcetransmission member coupling unit 42 of the actuator 38. The operativeforce transmission member section 44 further includes a crown couplingportion 48 coupled to a force transmission member coupling portion 50.For example, and referring to FIG. 13, where the force transmissionmember coupling portion 50 is a portion of the crown 26, the coupling ofthe crown coupling portion 48 to the force transmission member couplingportion 50 of the crown 26 is effected by stitching the crown couplingportion 48 to the force transmission coupling portion of the crown 26.In this respect, the operative force transmission member section 44extends from: the coupling unit 42 of the actuator 38 and rearwardlytowards the rear 52 of the crown 26, about the rear 52 of the crown 26and towards the other side of the crown 26, and to the forcetransmission member coupling portion 50. The actuator 38 is configuredto effect, when a head 14 is received within the crown 26, applicationof a force on the operative force transmission member section 44 suchthat the operative force transmission member section 44 changes itscondition relative to a surface fraction of a head 14 received withinthe crown 26 to any one of a plurality of conditions in response to anapplication force to the actuator 38, wherein, in at least one of theplurality of conditions, an operative surface of the operative section44 of the force transmission member 40 is bearing against a surfacefraction of the head 14 received within the crown 26. For example, theforce, whose application the actuator 38 is configured to effect, is atensile force. For example, with respect to the effect on the forcetransmission member 40 of applying a force to the actuator 38, whilechanging a condition of disposition relative to a head 14 receivedwithin the crown 26 in response to the application of force to theactuator 38, the force transmission member 40 changes position (ormoves) relative to the actuator 38, and, in doing so, effects a changein the length of the portion of the force transmission member disposedbetween the force transmission member coupling unit 42 and the forcetransmission member coupling portion 50 of the crown (i.e. a change inthe length of the fraction of the force transmission member 40 which isthe operative force transmission member section 44).

For example, and referring to FIG. 7, with respect to the forcetransmission member 40, the force transmission member 40 includes astrap, such as an elongated strap 56. For example, with respect to theelongated strap 56, the width of the elongated strap 56 is substantiallyuniform and the thickness of the strap 56 is substantially uniform. Forexample, with respect to the width of the elongated strap 56, the widthof the elongated strap 56 is substantially uniform, and thesubstantially uniform width is 19 millimetres. For example, with respectto the thickness of the elongated strap 56, with the exception of thecrown coupling portion 46 (see below), the thickness of the elongatedstrap 56 is substantially uniform, and the substantially uniformthickness is 0.7 millimetres. For example, with further respect to theelongated strap 56, the elongated strap 56 includes the operative forcetransmission member section 44 which includes the operative surface, andthe bearing of the operative force transmission member section 44 of thestrap 56 against the surface fraction of the head 14 received within thecrown 26 is effected by the operative surface. The operative surfaceincludes an operative surface area. For example, with respect to theoperative surface area, the operative surface area of the elongatedstrap 56 is from 2500 mm² to 3460 mm², depending on the desiredadjustment of the force transmission member 40 by the actuator 38. Forexample, with further respect to the operative force transmission membersection 44 of the elongated strap 56, the length of the operative forcetransmission member section 44 of the elongated strap 56 varies from 275millimetres to 295 millimetres, depending on the desired adjustment ofthe force transmission member 40 by the actuator 38. In larger-sizedheadwear, for example, the length of the operative force transmissionmember section varies from 325 millimetres to 345 millimetres, dependingon the desired adjustment of the force transmission member 40 by theactuator 38. For example, with respect to the disposition of theoperative force transmission member section 44 of the elongated strap 56relative to the crown 26, the lower edge 60 of the operative forcetransmission member section 44 of the elongated strap 56 is disposedabove a lower edge 62 of the crown 26 by a maximum vertical distance ofno more than 0.635 centimetres. For example, the lower edge 60 of theoperative force transmission member section 44 is disposed as close aspossible to the lower edge of the crown 26. For example, the elongatedstrap 56 is formed of plastic, such as BASF A3K™ Nylon 66.

A further example of the force transmission member 40 is illustrated inFIGS. 28A, 28B, and 28C. Exemplary dimensions provided in FIGS. 28A and28B are in millimetres. The force transmission member 40 includes thestrap 56. The force transmission member 40 includes a relatively harderstrap portion 4002 and a relatively softer strap portion 4004. Forexample, the relatively harder strap portion 4002 is made from plastic,such as BASF A3K™ Nylon. For example, the relatively softer strapportion 4004 includes a substantially inelastic (in the lateraldirection) strap portion 4006 and a resilient strap portion 4008. Forexample, the material of the substantially inelastic strap portion 4006is nylon ribbon. For example, a suitable nylon ribbon is No. 1 NylonRibbon supplied by Yama Ribbons & Bows Co. Ltd. of China. For example,the material of the resilient strap portion 4008 is woven fabricconsisting essentially of elastic and polyester. For example, a suitablewoven fabric for portion 2008 is Article No. AP602370ELW supplied byGolden Cedar Garment Accessories International Limited of Kwai Chang,New Territories, China. For example, the strap portion 4006 is attachedto the strap portion 4002 by stitching, and the strap portion 4008 isattached to the strap portion 4006 by stitching. For example, therelatively harder strap portion 4002 defines a strap insertion end 1063which is inserted into the actuator 38. The strap portion 4002 includesa plurality of strap pins 1060 which function as the actuator couplingportion 46. A chamfer 1062 may be provided on each of the strap pins1060, for purposes described below. A hard stop 1067 is also providedand includes a hole 1066 and one or more outward projections 1064. Thehard stop 1067 may be used as an alternative to the chamfer 1062 and/orin combination with the chamfer 1062. Elements 1060, 1062, 1064, 1066,and 1067 of the strap portion 4002 are discussed below in furtherdetail. The strap portion 4002 is further provided with a detent 4010defined by a raised surface portion 4012. The detent 4010 functions as astop, preventing the strap 56 from being pulled any further into theactuator 38.

For example, and referring to FIGS. 6 and 10 to 17, the headwear 10further includes a guide system 64 configured for guiding movement ofthe force transmission member 40 substantially about a section of theperimeter of the headwear 10, while the force transmission member 40 ismoving in response to an application of force to the actuator 38. Forexample, the guide system 64 facilitates guiding of the movement of theforce transmission member 40 within the interior of the crown 26. Forexample, with respect to the guide system 64, at least a portion of theguide system 64 is a guide member disposed between: (i) the forcetransmission member coupling unit 42 of the actuator 38, and (ii) theforce transmission member coupling portion 50. For example, with respectto the guide member, the guide member is a tubular member 66 whichreceives the force transmission member 40 as the force transmissionmember 40 is moving in response to an application of force to theactuator 38. For example, with respect to the tubular member 66, thetubular member 66 is disposed between: (i) the force transmission membercoupling unit 42 of the actuator 38, and (ii) the force transmissionmember coupling portion 50. For example, with further respect to thetubular member 66, the tubular member 66 is formed of a textile materialsheet which is stitched onto itself to create a tubular passage 68 forreceiving the force transmission member 40 as the force transmissionmember 40 is moving in response to an application of force to theactuator 38 and thereby changing its position relative to the actuatorcoupling unit 42 (see FIG. 5). For example, with respect to the textilematerial sheet, the textile material sheet is a wicking fabric such asnylon. For example, the tubular member 66 also functions as a sweatband.For example, the tubular member 66 is attached (such as by stitching) tothe interior surface of the crown 26. For example, the tubular member 66includes an aperture 72 through which the force transmission member 40extends for coupling to the actuator 38.

For example, the tubular member 66 is formed as follows. A textile sheetis cut in a long narrow length and is 6.35 to 7.62 centimetres in width.An access slit is provided on one side of the textile sheet, and thisfunctions as the aperture 72 to facilitate coupling of the forcetransmission member 40 to the actuator 38. For example, the access slithas a width of 9 mm to accommodate travel of the force transmissionmember 40.

Referring to FIGS. 10 and 11, the actuator 38 is stitched to the textilesheet on the side on which the slit is provided. After the actuator 38is stitched to the textile sheet, the textile sheet is folded andstitched onto itself to form the tubular member 66. Referring to FIGS.13, 14, 15 and 16, the tubular member 66 is then stitched proximate tothe lower edge of the crown 26. Referring to FIGS. 12, 14, and 15, theforce transmission member 40 is inserted through the open end of thetubular member 66 furthest from the actuator 38, and is then fed throughthe tubular member 66 and out through the aperture 72. Once extendingthrough the aperture 72, the force transmission member 40 is coupled tothe actuator 38. The end of the operative section 44 of the forcetransmission member 40, remote from the end which has been coupled tothe actuator 38, is stitched to the crown 26 at the force transmissioncoupling portion 50. For example, the force transmission couplingportion 50 is disposed at the seam tape 70. The tubular member 66 isthen positioned such that the actuator 38 becomes disposed in oppositionto an aperture 261 provided in the crown 26. The crown edge defining theaperture 261 is itself defined by a reinforcing stitch for mitigatingfraying of the crown edge. For example, a trim ring 263 is stitched tothe crown 26 about the perimeter of the aperture 261. The trim ring 263is provided for the aesthetic purpose of concealing the reinforcingstitch provided about the perimeter of the aperture 261. The actuator 38is pushed through the trim ring 263, thereby becoming disposed andextending externally relative to the crown 26 (see FIG. 17).

In an alternative embodiment, and referring to FIG. 14A, a guard 88 isprovided. The functions of the guard 88 are further explained below. Theguard 88 is in the form of a plastic sheet including an aperture 89. Forexample, the plastic is polyurethane or polyvinylchloride. The aperture89 is snapped over a knob 1042 of the actuator 38 prior to pushing theactuator 38 through the trim ring 236, thereby effecting positioning ofthe guard 88 against a interior position of the crown 26.

For example, with respect to the relationship between the forcetransmission member 40 and the guide system 64, the force transmissionmember 40 co-operates with the guide system 64 during movement of theforce transmission member 40 (in response to an application of force tothe actuator 38) such that vertical movement of the operative forcetransmission member section 44 is limited during movement of the forcetransmission member 40 relative to the actuator 38. For example, withrespect to the limiting of the vertical movement of the operative forcetransmission member section 44, at least a fraction of the operativeforce transmission member section 44 is disposed relative to the guidesystem 64 such that a clearance is defined for limiting verticalmovement of any fraction of the operative force transmission membersection 44 within a range.

FIG. 18 illustrates an embodiment of the actuator 38 coupled to a strap56 of the force transmission member 40 from a perspective view. Asdepicted in this drawing, the actuator 38 is in the form of a camassembly 1030 which may comprise housing 1044, a knob 1042, a cam 1040,and a track insert 1046. The cam assembly 1030 and housing 1044 may beadapted to receive a strap 56. The cam assembly 1030 and strap 56 may bemade from numerous materials including various plastics, metals,composites, polymers, and alloys. In the illustrated embodiment, thehousing 1044 has a track insert 1046 positioned inside the housing 1044.The track insert 1046 may be adapted to allow a strap 48 to move in bothan inwards and outwards direction. The housing 1044 has a first opening1050 and a second opening 1052, which may be configured to receive astrap 1048 moving in both an inwards and outwards direction as well. Insome embodiments, the track insert 1046 may be integrally formed withthe housing 1044.

As further depicted in FIG. 18, the cam assembly 1030 has a knob 1042and a cam 1040. In some embodiments, once the cam 1040 has beencorrectly positioned, and the knob 1042 is positioned over the cam 1040,the two can be snapped together using a locking mechanism.Alternatively, the cam 1040 and knob 1042 may be adhered together,stitched together, divided into three or more components, be a singlecomponent, or use other attachment means. The cam 1040 includes theforce transmission member coupling unit 42.

The strap 56 may comprise one or more strap pins 1060. In someembodiments the strap pins 1060 may be a pointed piece of wood, metal,or plastic. In some embodiments the strap pins 1060 may be a short rod.In some embodiments, the strap pins 1060 may be projections, teethgrooves, channels, and/or other variations and combinations. The strappins 1060 include the actuator coupling portion 46.

FIGS. 19A, 19B and 19C illustrate the cam assembly 1030 and strap 56based closure system of FIG. 18 from a side, top, and bottom view, inaccordance with some embodiments of the inventions. As depicted in theside view of the FIG. 19A, by rotating the knob 1042 in one directionthe strap 56 can be pulled into the cam assembly 1030 through the firstopening 1050, onto the track insert 1046 (not visible from this view),through the second opening 1052, and out of the housing 1044. As furtherdepicted in FIG. 19A, by rotating the knob 1042 in another direction thestrap 56 can be pulled back through the track insert 1046 (not visiblefrom this view), through the first opening 1050, and out of the housing1044. The strap 56 is driven through the cam assembly 1030 when thestrap pins 1060 engage with the cam 1040.

As further depicted in the top view of FIG. 19B, in some embodiments thecam 1040 sits inside the knob 1042. The knob 1042 may then be rotated todrive the strap 56 through the first opening 1050 into the cam assembly1030, and out the second opening 1052.

As depicted in the bottom view of FIG. 19C, in some embodiments, thetrack insert 1046 is positioned to sit inside the housing 1044. The cam1040 is then positioned to sit above the track insert 1046 on top of thehousing 1044. The cam may include one or more cam spirals 1041 thatcause the strap pins 1060 on a strap 56 to be pulled through the camassembly 1030.

FIGS. 20A, 20B, 20C, and 20D illustrate the cam 1040 of FIG. 18 from atop, bottom, and perspective views, in accordance with some embodimentsof the inventions. As depicted in the top view of FIG. 20A, the cam mayhave a crown 1047 that may be placed in one or more channels or grooveson the knob 1042 that are fitted to the cam 1040, and allow the cam 1040to attach to the knob 1042. In some embodiments, once the cam 1040 hasbeen correctly positioned, and the knob 1042 is positioned over the cam1040, the two are configured to be snapped together using a lockingmechanism. Alternatively, the cam 1040 and knob 1042 may be adheredtogether, divided into three or more components, or be a singlecomponent.

As further depicted in the bottom and perspective views of FIGS. 20B,and 20C, in some embodiments, the cam 1040 contains one or more camspirals 1041. The knob 1042 may then be rotated to drive the strap 56through the first opening 1050 into the cam assembly 1030, and out thesecond opening 1052. In some embodiments, the cam spirals 1041 are inthe shape of logarithmic spirals, also known as equiangular spirals. Insome embodiments, other types of spirals may be used, includingArchimedean spirals. In some embodiments, two, three, four, or more camspirals 1041 may be used. Increasing the number of cam spirals 1041 maybe used to increase the speed at which the strap 56 is inserted. Thismay be particularly useful for applications where the closure is large.

The use of cam spirals 1041 may allow the strap 56 to self-lock into thecam assembly 1030 at certain contact angles. Logarithmic spirals mayallow the strap pins 1060 on the strap 56 to be pulled at a linearvelocity and constant contact angle. Different materials may also beused to vary the friction coefficients and make the system self-locking.Self-locking may allow the strap 56 to remain in the same position inthe cam assembly 1030 when outwards forces and/or inwards forces areapplied to the cam 1040 and/or strap 56. When logarithmic cam spiralsare used, a constant angle of contact may be maintained with the strappins 1060 on the strap 56, resulting in a self-locking system that maybe infinitely adjustable, and one where the torque felt by the knob 1042may be constant. However, an Archimedean spiral may be used to vary thecontact angle, such as by continuously decreasing it.

The self-locking mechanism may be determined by the contact angle 1045and the friction applied to the circumference of the cam spirals 1041 onthe cam 1040. The contact angle 1045 may correspond to an angle betweenlines tangent to a strap pin 1060 and a cam spiral 1041. In someembodiments, the contact angle 1045 of a self-locking mechanism may beless than 20 degrees, and less than 15 degrees. In some self-lockingembodiments, the contact angle is between 10 and 12 degrees. Low contactangles may allow the cam assembly 1030 to be self-locking andcontinually adjustable both inwards and outwards. Various contact anglescan be generated depending on the speed of wind and power desired.Larger contact angles 1045 may result in faster insertion speed. Othersecondary frictional elements can also be added to resist the turning ofthe cam 1040. In some embodiments, these secondary frictional elementsmay be “stepless” to maintain infinite variability of position.

FIGS. 7 and 7B illustrate the strap 1048 of FIG. 18 from a perspectiveand top view, in accordance with some embodiments of the inventions. Thestrap 56 comprises one or more strap pins 1060. The strap pins 1060 maybe in the shape of cylinders extending from the surface of the strap 56as illustrated. In some embodiments, the strap pins 1060 may be othershapes including but not limited to rivets, teeth, threads, spirals,spiral threads, slots, strips, channels, and/or grooves that may beperpendicular or at other angles to the strap 56. In some embodiments,the cam 1040 may have cam spirals 1041 in complementary form and/orsurfaces that may be complementary or correspond to the shape of thestrap pins 1060.

In some embodiments, the strap 56 may have a chamfer 1062 on the firststrap pin closest to the cam assembly insertion end 1063, to allow thefirst strap pin to skip past the cam 1040. The chamfer 1062 may be at arange of angles, including 45 degrees. The chamfer 1062 may alsomaintain engagement between the cam 1040 and the strap 56 to ensure thatthey continue to function. In some embodiments, a chamfer 1062 may be onother strap pins 60, including the last strap pin furthest from the camassembly insertion end 1063 of the strap 56. In some embodiments, achamfer 1062 may be included on the last strap pin, in addition to, orin lieu of, being on the first strap pin.

In some embodiments, the chamfer 1062 on the last strap pin may face theopposite direction of the chamfer 1062 on the other strap pins. Thechamfer 1062 on the last strap pin may prevent the cam spirals 1041 frompulling the strap 56 further into the cam assembly 1030. In someembodiments, the chamfer 1062 on the first strap pin, may keep the strap56 from being pushed any further out of the cam assembly 1030 and/or thechamfer 1062 on the last strap pin may prevent the strap 56 from beingpulled any further into the cam assembly 1030.

In some embodiments, the hard stop 1067 described in greater detailbelow, may be used as an alternative to the chamfer 1062 and/or incombination with the chamfer 1062. In some embodiments, the hard stop1067 may be located near the first strap pin and/or last strap pin. Insome embodiments, the hard stop 1067 may not include a hole 1066 whenused in conjunction with the chamfer 1062 on the last strap pin. In someembodiments, this may prevent the strap 56 from compressing and enteringinto the cam assembly 1030 regardless of the pressure applied to thestrap 56.

As further depicted in FIGS. 7 and 7B, the strap 56 has a cam assemblyinsertion end 1063 which is the end of the strap 56 that is inserteddirectly into the cam assembly 1030. The strap 56 may be configured toresist being completely removed from the cam assembly 1030 afterinsertion. In some embodiments, this resistance may be provided by ahard stop 1067. In some embodiments, the hard stop 1067 may be avariable stop that may be overcome given enough force. In someembodiments, the hard stop 1067 may be placed near the first strap pin,the last strap pin, near other strap pins and/or multiple hard stops maybe used.

The hard stop 1067 may include a hole 1066 and one or more outwardprojections 1064. The hole 1066 may allow the outward projections 1064to compress toward the axial center line of the strap 56 to allow thestrap 56 to be inserted into the housing 1044 of the cam assembly 1030.Gently tapered leading edges 1064 a allow the strap 56 to enter thehousing 1044 with relative ease. More steeply tapered trailing edges1064 b make it more difficult to remove the strap 56 from the housing1044. In some embodiments, the trailing edge 1064 b may catch the strap56 on the housing 1044 to prevent the strap from falling out of thehousing 1044 and may leave the strap 56 in a position to be pulled backin, i.e. in a position such that the first strap pin is in a position tobe engaged by the cam spirals 1041 as soon as the knob 1042 is rotatedin the tightening direction. In some embodiments, if enough force isused to pull the strap 1048 out of the housing 1044 the outwardprojections 1064 can temporarily collapse into the hole 1066 and thestrap 56 may be removed.

FIGS. 21A, 21B, and 21C illustrate the track insert 1046 of FIG. 18 froma perspective, top, and side view, in accordance with some embodimentsof the inventions. The track insert 1046 has a tunnel 1072 that pullsthe strap 56 away from the cam 1040 as it is passed through the tunnel1072. In some embodiments, the track insert guides the strap 1048 alongand engages the strap 56 with the cam 1040 along a front edge 1070 butthen disengages the strap 56 on the back edge 1074. In some embodiments,the track insert 1046 pulls the strap 56 away from the cam 1040 so thatthe cam spirals 1041 are engaged in a reduced number of the strap pins1060 on the strap 56 relative to the number of strap pins 1060 withinthe housing 1044. In some embodiments, the number of strap pins 1060engaged at any given time is one or two. This guide component or bendback mechanism may be a tunnel and/or S-shape bend and/or an arc whichallows the strap pins 1060 to disengage the cam spirals 1041 of the cam1040. In some embodiments, the strap pins 1060 are guided away from thecam spirals 1041 such that fewer than all of the cam spirals 1041 engagethe strap pins 1060 when the strap 56 extends through the housing 1044.

In some embodiments, the guide component pulls the strap 56 away fromthe cam 1040 so that the strap pins 1048 do not engage on the backsideof the cam 1040. In some embodiments, the guide component prevents thesystem from locking up and/or may strengthen the system by bringing thestrap in parallel to the cam 1040 for maximum holding strength. In someembodiments, the load placed on the cam assembly 1030 by the strap 56may be a shear load, which places a stress parallel or tangential to thecam assembly 1030. The guide component is particularly useful inproviding the lowest possible height and/or profile of the housing 1044.The guide component may also allow the strap 56 to be fed into the camassembly 1030 without catching on the cam 1040.

FIGS. 22A, 22B, 22C, and 22D illustrate the housing 1044 of FIG. 18 froma perspective, side, top, and bottom view, in accordance with someembodiments of the inventions. The housing 1044 has a first opening 1050and a second opening 1052, which are configured to receive a strap 1048moving in both an inwards and outwards direction. In the illustratedembodiment, the housing also has a circular opening 1080, which allowsthe track insert 1046 to be positioned inside the housing 1044. Thecircular opening 1080 need not be in the shape of a circle, and may bein the form of other shapes including a square, oval, or triangle. Insome embodiments, the cam 1040 and the knob 1042 may be attached to eachother, using a locking mechanism, an adhesive or any other attachmentmechanism or method known to those of skill in the art. The knob 1042and cam 1040 are then positioned in the circular opening 1080 of thehousing 1044, to sit above the track insert 1046 and on top of thehousing 1044. The knob 1042 may then be rotated to drive the strap 1048through the first opening 1050, onto the track insert 1046, and out thesecond opening 1052 of the housing 1044.

As further depicted in FIGS. 22A, 22B, 22C, and 22D, in someembodiments, the housing 1044 has a bend 1086 that may be an S-shapebend and/or an arc. The bend 1086 may match the shape of the bend backmechanism of the track insert 1046. The bend 1086 is particularly usefulin providing the lowest possible height and/or profile of the housing1044. In some embodiments, the shape of the housing 1044 may be adjustedbased on the application. In some embodiments, the shape of the housing1044 may be flatter or more curved than an S-shape or an arc.

FIG. 23 illustrates the knob 1042 of FIG. 18 from a perspective view, inaccordance with some embodiments of the inventions. The knob 1042 has anovermold 1092 and an undermold 1100. In some embodiments, once theundermold 1100 has been correctly positioned, and the overmold 1092 ispositioned over the undermold 1100, the two can be snapped togetherusing a locking mechanism. Alternatively, the undermold 1100 andovermold 1092 may be adhered together, divided into three or morecomponents, or be a single component. In some embodiments, the overmold1092 may be injection molded around a pre-made undermold 1100.

As further depicted in FIG. 23, in some embodiments, the knob 1042 has acam opening 1090. The cam opening 1090 allows the cam 1040 to sit insidethe knob 1042. The cam opening 1090 need not be any particular shape,and may be in the form of any shape including a circle, square, oval, ortriangle. Once assembled, the knob 1042 may be rotated to drive thestrap 1048 through the first opening 1050, into the cam assembly 1030,and out the second opening 1052.

FIG. 24 illustrates the overmold 1092 of the knob of FIG. 23 from abottom view, in accordance with some embodiments of the inventions. Insome embodiments, the overmold 1092 also has one or more overmold teeth1094. In this embodiment, the overmold teeth 1094 allow the overmold1092 and the undermold 1100 to be snapped together and unitized when theundermold 1100 has corresponding teeth that fit in the one or moreovermold grooves or channels 1096 of the overmold 1092. In someembodiments, the overmold 1092 has a cam opening 1090, which may allowdifferent designs or colors to be used. As with the other cam openings,it may be in the form of any shape including a circle, square, oval, ortriangle. In some embodiments, the overmold 1092 does not include thecam opening 1090.

FIGS. 25A and 25B illustrate the undermold 1100 of the knob 1042 of FIG.23 from a perspective and bottom view, in accordance with someembodiments of the inventions. In some embodiments, the undermold 1100has a cam opening 1090, which allows the cam 1040 to sit inside the knob1042. As previously mentioned the cam opening 1090 may be in the form ofany shape including a circle, square, oval, or triangle. In someembodiments, the undermold 1100 also has one or more undermold teeth1102. In some embodiments, the undermold teeth 1102 allow the undermold1100 and the overmold 1092 to be snapped together and unitized when theovermold 1092 has corresponding overmold teeth 1094 that fit in the oneor more undermold grooves or channels 1108 of the undermold 1100. Asdescribed above, in some embodiments the overmold 1092 may be injectionmolded around a pre-made undermold 1100. In some embodiments, the cam1040 and the knob 1042 may be a single component; two components; threecomponents, such as an overmold 1092, an undermold 1100, and a cam 1040;or four or more components.

As further depicted in the bottom view of FIG. 25B, the undermold 1100of the knob 1042 may have one or more cam channels or grooves 1106. Aspreviously discussed, in some embodiments, the cam channels 1106 may befitted to the shape of the crown 1047 of the cam 1040, and allow the cam1040 to attach to the knob 1042. In some embodiments, once the cam 1040has been correctly positioned, and the knob 1042 is positioned over thecam 1040, the two may be snapped together using a locking mechanism orinterference fit. In another embodiment, the crown may be placed on theknob 1042 and channels matching the shape of the knob crown on the cam1040. Yet alternatively, the cam 1040 and knob 1042 may be adheredtogether, divided into three or more components, be a single component,or attached using other means. In some embodiments, the outer edge ofsome or all of the knob 1042 may include friction enhancing featuressuch as outward projections or inwards grooves to increase the tractiona user's hand would have on the knob 1042.

FIGS. 26A, 26B, 26C, 26D, 26E, and 26F illustrate a flowchart of theengagement of the strap pins 1060 of FIG. 7A with the cam spirals 1041of FIG. 20C when the strap 56 of FIG. 18 is being driven into the camassembly 1030 of FIG. 18, in accordance with some embodiments of theinventions. Proceeding alphabetically, each figure represents theprogression of the strap 56 into the cam assembly 1030 over subsequentsteps of time. The cam spirals 1041 of the cam 1040 may drive the strap56 into the cam assembly 1030, and may engage them at a constant angle.In some embodiments, a lower contact angle may be chosen toautomatically lock the strap 56 into the cam assembly 1030.Alternatively, higher contact angles may be chosen to increase the windspeed. If the cam assembly 1030 is not self-locking, an external locksuch as a button or lever may be incorporated to allow the user to lockthe cam assembly 30 in a desired location. In some embodiments, wherethe cam assembly 1030 is self-locking, a secondary locking mechanism isstill provided to ensure the closure system remains in position whenforce is applied in the inwards and/or outward directions.

FIGS. 27A, 27B, 27C, 27D, 27E, and 27F illustrate a flowchart of theengagement of the strap pins 1060 of FIG. 4A with the cam spirals 1041of FIG. 20C when the strap 56 of FIG. 18 is being driven out of the camassembly 1030 of FIG. 18, in accordance with some embodiments of theinventions. Proceeding alphabetically, each figure represents theprogression of the strap 56 out of the cam assembly 1030 over subsequentsteps of time. The cam spirals 1041 of the cam 1040 drive the strap 56out of the cam assembly 1030, and may engage them at a constant angle.In some embodiments, a lower contact angle may be chosen toautomatically lock the strap 56 into the cam assembly 1030.Alternatively, higher contact angles may be chosen to increase the windspeed.

(A) Configuration of Adjustment System for Effecting Bearing of HeadwearAgainst Head

In one aspect, the headwear 10 includes an adjustment system configuredfor effecting bearing of the headwear 10 against a surface fraction ofthe head 14 received within the crown 26 of the headwear 10.

As discussed above, by virtue of the coupling of the actuator 38 to theforce transmission member 40, the actuator 38 is configured to effect,when a head 14 is received within the crown 26, and relative to a head14 received within the crown 26, a change in disposition of the forcetransmission member 40 to any one of a plurality of conditions inresponse to an application of force to the actuator 38. In at least oneof the plurality of conditions, the operative surface of the operativesection 44 of the force transmission member 40 is bearing against asurface fraction of the head 14 received within the crown 26.

Referring, in particular to FIGS. 1 to 3, in one sub-aspect, the surfacefraction of the head 14 (against which the force transmission member 40is bearing) is disposed rearwardly of the forehead and extendssubstantially continuously from a point within a distance of 5.08centimetres from a first temple reference plane 16 defined by one of thetemples of one side of the head 14, wherein the distance is measuredalong an axis normal to the plane 16 and rearwardly towards the rear 52of the head 14, about the rear 52 of the head 14 and towards the otherside of the head 14, and to a point within a distance of 5.08centimetres from a second temple reference plane 18 defined by the otherone of the temples of the other side of the head 14, wherein thedistance is measured along an axis normal to the plane 18. In thiscontext, ‘substantially continuously” means that there may bediscontinuous portions of the surface fraction against which theoperative section 44 does not bear, and that the surface fraction isregarded as being substantially continuous as long as the bearing of thetwo operative section 44 effects mounting of the headwear 10 to the head14 in a desired position (but not necessarily a permanently fixedposition, and it is understood that application of relatively minorforces to the headwear, such as that which may be applied by a humanhand, may be sufficient to dislodge the headwear 14 from the desiredposition) relative to the head.

In each one of the at least one of the plurality of conditions where theoperative surface is bearing against a surface fraction of a headreceived within the crown, the bearing of the operative surface againstthe surface fraction of the head is limited to a surface fractiondisposed rearwardly of the forehead. If only for greater clarity, theoperative surface of the operative force transmission member section 44is configured to bear only against a surface fraction of the head 14disposed rearwardly of the forehead of the wearer, and does not bearagainst the forehead of the wearer in any one of the plurality ofconditions which the operative force transmission member is configuredto assume when a head is received within the crown 26.

In a related sub-aspect, the force transmission member 40 includes acrown coupling portion 48 attached to the force transmission membercoupling portion 50. As such, the operative section 44 of the forcetransmission member 40 extends from: the actuator coupling unit 42 andrearwardly towards the rear 52 of the crown 26, about the rear 52 of thecrown 26 and towards the other side of the crown 26, and to the forcetransmission member coupling portion 50. The actuator 38 is configuredto effect, when a head 14 is received within the crown 26, anapplication of a force to the operative force transmission membersection 44, such that the operative force transmission member section 44changes its condition relative to a surface fraction of a head 14received within the crown 26 to any one of a plurality of conditions inresponse to the application of force to the actuator 38. In at least oneof the plurality of conditions, the operative surface of the operativeforce transmission member section 44 is bearing against a surfacefraction of the head 14 received within the crown 26. For example, theforce whose application is effected by the actuator 38 is a tensileforce. The coupling unit 42 of the actuator 38 is disposed at one sideof the headwear 10, and between a front and a rear 52 of the headwear10, and the force transmission member coupling portion 50 is disposed ata side of the headwear 10 opposite to the side on which the couplingunit 42 of the actuator 38 is disposed, and between a front and a rear52 of the headwear 10. For example, with respect to the dispositions ofthe actuator 38 and the force transmission coupling portion 50, theactuator 38 is disposed relatively closer to the front of the headwear10 than the rear 52 of the headwear 10, and the force transmissionmember coupling portion 50 is disposed relatively closer to the front ofthe headwear 10 than the rear 52 of the headwear 10. In each one of theat least one of the plurality of conditions where the operative surfaceis bearing against a surface fraction of a head received within thecrown, the bearing of the operative surface against the surface fractionof the head is limited to a surface fraction disposed rearwardly of theforehead. If only for greater clarity, the operative surface of theoperative force transmission member section 44 is configured to bearonly against a surface fraction of the head 14 disposed rearwardly ofthe forehead of the wearer, and does not bear against the forehead ofthe wearer in any one of the plurality of conditions which the operativeforce transmission member is configured to assume when a head isreceived within the crown 26.

In a further related sub-aspect, with respect to the dispositions of theactuator 38 and the force transmission member coupling portion 50, thedistance from the most rearward edge of the actuator coupling unit 42 tothe first temple reference plane 16 is less than 5.08 centimetres,wherein the distance is measured along the longitudinal axis 58 of theforce transmission member 40, and the distance from the most rearwardedge of the force transmission member coupling portion 50 to the secondtemple reference plane 18 is less than 5.08 centimetres, wherein thedistance is measured along the longitudinal axis 58 of the forcetransmission member 40. For example, with respect to the distance,measured along the axis 58, from the most rearward edge of the actuatorcoupling unit 42 to the first temple reference plane 16, this distanceis 2.54 centimetres. For example, with respect to the distance, measuredalong the axis 58, from the most rearward edge of the force transmissionmember coupling portion 50 to the second temple reference plane 18, thisdistance is 2.54 centimetres.

For example, where the headwear 10 further includes a peak 30, withrespect to the dispositions of each one of the actuator 38 and the forcetransmission coupling portion 50, the force transmission member couplingportion 50 is disposed on an opposite side of the peak 30 relative tothe disposition of the actuator 38. For example, with further respect tothe disposition of the actuator 38 and the force transmission membercoupling portion 50, the actuator 38 is disposed closer to the peak 30than to the rear 52 of the headwear 10, and the force transmissionmember coupling portion 50 is disposed closer to the peak 30 than to therear 52 of the headwear 10. With further respect to the disposition ofthe force transmission member coupling portion 50, the minimum distancefrom the most rearward edge of the force transmission member couplingportion 50 of the crown 26 to the attachment between the crown 26 and aportion of the peak 30 is less than 5.08 centimetres, the minimumdistance being measured along a side surface of the crown which includesthe portion 50. For example, this minimum distance is equal to or lessthan 0.159 centimetres. For example, with respect to the peak portion towhich the crown 26 is attached, the peak portion is more rigid than theforce transmission coupling portion. Suitable crown and peak materialsare described above.

(B) Force Transmission Member Including Resilient Portion

In another aspect, and referring to FIGS. 7 and 9, the operative forcetransmission member section 44 includes a relatively rigid portion 74and a relatively resilient portion 76.

In this respect, the length of the relatively resilient portion 76 is atleast 5.5% of the length of the operative force transmission membersection 44. For example, the length of the relatively resilient portion76 is less than 18.5% of the length of the operative force transmissionmember section 44. For example, the relatively resilient portionincludes a length of about one (1) inch.

For example, with respect to the relatively rigid portion 74, thematerial of the relatively rigid portion 74 is a plastic, such as BASFA3K™ Nylon 66. For example, with respect to the relatively resilientportion 76, the material of the relatively resilient portion 76 is wovenfabric consisting essentially of elastic and polyester. For example, thematerial of the relatively resilient portion consists essentially ofelastic and polyester, and the ratio of the volume of elastic to thevolume of polyester is 2:3. For example, the resilient portion 76 isArticle No. AP602370ELW, supplied by Golden Cedar Garment AccessoriesInternational Limited of Kwai Chang, New Territories, Hong Kong. Forexample, the relatively resilient portion 76 is attached to the forcetransmission coupling portion, such as by stitching.

For example, by providing the resilient portion 76, when the operativesection 44 is released from the actuator coupling unit 38, the forcetransmission member 40 returns to an original unactuated condition.

(C) Force Transmission Member Including Softer/More Flexible Portion

In another aspect, and referring to FIGS. 28A, 28B, and 28C, theoperative force transmission member section 44 includes a relativelyharder (or less flexible) portion 4012 and a relatively softer (or moreflexible) portion 4004. For example, each one of the portions 4002 and4014 are in the form of strap portions 4002, 4004, respectively. Forexample, strap portion 4002 includes a strap insertion end 1063 forinsertion into the actuator 38, to thereby facilitate coupling with theactuator 38. For example, the strap portion 4002 is attached to thestrap portion 4004 by stitching. For example, the strap portion 4004 iscoupled to the coupling portion 50 of the crown 26 by stitching. Forexample, the relatively harder strap portion 4002 is made from aplastic, such as BASF A3K™ Nylon. For example, the relatively softerstrap portion 4004 includes a substantially inelastic (in the lateraldirection) strap portion 4006 and a resilient strap portion 4008. Forexample, the material of the substantially inelastic strap portion 4006is nylon ribbon. For example, a suitable nylon ribbon is No. 1 NylonRibbon supplied by Yama Ribbons & Bows Co. Ltd. of China. For example,the material of the resilient strap portion 4008 is woven fabricconsisting essentially of elastic and polyester. For example, thematerial of the relatively resilient portion consists essentially ofelastic and polyester, and the ratio of the volume of elastic to thevolume of polyester is 2:3. For example, the material of the resilientportion 4008 is Article No. AP602370ELW, supplied by Golden CedarGarment Accessories International Limited of Kwai Chang, NewTerritories, Hong Kong.

The length of the relatively harder portion 4002 is less than 33.9% ofthe length of the operative force transmission member section 44. Forexample, the length of the relatively harder portion 4002 is less than33% of the length of the operative force transmission member section 44.For example, the length of the relatively resilient strap portion 4006is at least 5.5% of the length of the operative force transmissionmember section 44. As a further example, the length of the relativelyresilient strap portion is less than 18.5% of the length of theoperative force transmission member section 44. For example, therelatively resilient strap portion 4008 includes a length of about one(1) inch.

For example, by providing the resilient portion 4008, when the operativesection 44 is released from the actuator coupling unit 38, the forcetransmission member 40 returns to an original unactuated condition.

(D) First Mode of Coupling of the Force Transmission Member to the Crown

In another aspect, the headwear 10 is configured so that the forcetransmission member 40 is robustly coupled to a force transmissioncoupling portion of the crown 26.

In this respect, and referring, in particular, to FIG. 5, the headwear10 includes the crown 26, the peak 30, the actuator 38, and the forcetransmission member 40. The force transmission member 40 is coupled tothe coupling unit 42 of the actuator 38. By virtue of such coupling, theactuator 38 is configured to effect disposition of the forcetransmission member 40 relative to a head 14 received within the crown26 in any one of a plurality of conditions, in response to anapplication of force to the actuator 38. In at least one of theplurality of conditions, the operative surface of the operative section44 of the force transmission member 40 is bearing against a surfacefraction of the head 14 received within the crown 26. The forcetransmission member 40 is also coupled to the crown 26. In this respect,the force transmission member 40 includes a crown coupling portion 48attached to the force transmission member coupling portion 50 of thecrown 26. The headwear further includes the peak 30. With respect to thecoupling of the force transmission member 40 to the crown 26, the crowncoupling portion 48 is attached to the crown 26 at the forcetransmission member coupling portion 50, and the minimum distance fromthe force transmission member coupling portion 50 of the crown 26 to apoint of attachment 78 between the crown 26 and a portion of the peak 30is less than 5.08 centimetres, the minimum distance being measured alonga side surface of the crown which includes the portion 50. For example,the minimum distance is less than 0.159 centimetres. For example, withrespect to the peak portion to which the crown 26 is attached, the peakportion is more rigid than the force transmission coupling surface.Suitable crown and peak materials are described above.

For example, and also referring to, in particular, FIG. 13, the crown 26includes two adjacent panels 28 which are attached to one another alongrespective and abutting sides, such as by stitching, to define a seam,and seam tape 70 is applied across the seam and joined to each one ofthe two adjacent panels 70. The seam tape 70 extends upwardly proximateto a portion of the peak 30. For example, the peak portion is more rigidthan the force transmission member coupling portion 50 of the crown 26.The force transmission member coupling portion 50 of the crown 26 isdisposed relative to the seam tape 70 such that the force transmissionmember coupling portion 50 of the crown 26 is disposed at the seam tape70, and the minimum distance between: (i) the force transmission membercoupling portion 50 of the crown 26, and (ii) a point of attachment 78between the seam tape 70 and the portion of the peak 30, is less than5.08 centimetres, the minimum distance being measured along the seamtape 70. For example, the minimum distance is less than 0.159centimetres.

(E) Second Mode of Coupling of the Force Transmission Member to theCrown

The headwear 10 is also configured with other aspect(s) so that theforce transmission member 40 is robustly coupled to a force transmissioncoupling portion of the crown 26.

In this respect, and referring, in particular to FIGS. 5 and 13, theheadwear 10 includes the crown 26, the peak 30, the actuator 38, and theforce transmission member 40. The force transmission member 40 iscoupled to the coupling unit 42 of the actuator 38. By virtue of suchcoupling, the actuator 38 is configured to effect disposition of theforce transmission member 40 relative to a head 14 received within thecrown 26 in any one of a plurality of conditions, in response to anapplication of force to the actuator 38. In at least one of theplurality of conditions, the operative surface of the operative section44 of the force transmission member 40 is bearing against a surfacefraction of the head 14 received within the crown 26. The forcetransmission member 40 is also coupled to the crown 26. In this respect,the force transmission member 40 includes a crown coupling portion 48attached to the force transmission member coupling portion 50 of thecrown 26. The crown 26 includes two adjacent panels 28 which areattached to one another along respective and abutting sides to define aseam. For example, the adjacent panels 28 are attached to one another bystitching. Seam tape 70 is disposed across the seam and joined to eachone of the adjacent panels 28. For example, the seam tape 70 extendsupwardly from proximate to a portion of the peak 30. For example, thepeak portion is more rigid than the force transmission member couplingportion 50 of the crown 26. The force transmission member couplingportion 50 of the crown 26 is disposed relative to the seam tape 70 suchthat the force transmission member coupling portion 50 of the crown 26is disposed at the seam tape 70.

(F) First Configuration of Force Transmission Member

In another aspect, the force transmission member 40 is configured tofacilitate air flow across the operative force transmission membersection 44. For example, this configuration also mitigates frictionallosses during movement of the force transmission member 40.

In this respect, and referring to, in particular, FIG. 7, the ratio of(i) the operative surface area of an operative surface fraction 441 ofat least a fraction of the operative force transmission member section,to (ii) a length of the at least a fraction 441, is from 6.3 mm²/mm to13.6 mm²/mm. For example, with respect to the at least a fraction 441 ofthe operative force transmission member section 44, the ratio is 8.1mm²/mm. The at least a fraction 441 of the operative force transmissionmember section 44 defines at least 50% of the length of the operativeforce transmission member section 44. For example, the at least afraction 441 defines 70% of the length of the operative forcetransmission section 44.

The at least a fraction includes at least one portion of the operativeforce transmission member section 44. Each one of the at least oneportion includes a respective operative surface portion and a respectiveportion length. The operative surface of the operative forcetransmission member section 44 includes each one of the respectiveoperative surface portions.

Each one of the operative surface fraction and the length of the atleast a fraction 441 of the operative force transmission member section44 is defined as follows. Referring to FIG. 7 where the at least oneportion is one portion 441 a of the operative force transmissionsection, the operative surface fraction is defined by the respectiveoperative surface portion of the one portion and the length of the atleast a fraction 441 is defined by the respective portion length of theone portion 441 a. Referring to FIG. 7A, where the at least one portionis at least two portions 441 b and 441 c of the operative forcetransmission member section, the operative surface fraction is definedby the combination of the respective operative surface portions of theat least two portions 441 a, 441 b and the length of the at least afraction 441 is defined by the sum of the respective portion lengths ofthe at least two portions 441 a, 441 b.

It is understood that each portion of the operative force transmissionmember section 44 is a continuous material, such that each portion isspaced apart from each and every other portion. Referring to FIG. 7, forexample, the at least a fraction is a single portion of continuousmaterial.

By providing a force transmission member 40 including this relationshipbetween the operative strap surface area of the at least a fraction 441of the operative force transmission section 44 and the length of the atleast a fraction 441 of the operative force transmission member section44, air flow across the operative force transmission member section 44is facilitated. For example, this configuration also mitigatesfrictional losses arising during movement of a force transmission member40, while still providing a force transmission member 40 which feelscomfortable to the wearer of the headwear 10 as the force transmissionmember 40 is bearing against the surface fraction of the head 14received within the crown 26.

For example, and referring to FIG. 7, the at least a fraction 441 of theoperative force transmission member section 44 includes a plurality ofspaced apart apertures 82. For example, the at least a fraction 441 ofthe operative force transmission member section 44 Is a single portionof the operative force transmission member section 44, and the singleportion includes a plurality of substantially equally spaced apartapertures 82.

For example, the minimum width of the at least a fraction 441 of theoperative force transmission member section 44 is at least 13millimetres.

For example, and referring to FIG. 9, the at least a fraction 441 of theoperative force transmission member section 44 includes alternatingwider and narrower portions 86 along the length of the at least afraction 441 of the operative force transmission member section 44 ofthe force transmission member 40. For example, and referring to FIG. 7,with further respect to the width of the at least a fraction 441 of theoperative force transmission member section 44, the width of the atleast a fraction of the operative force transmission member section 44is substantially uniform throughout the length of the at least afraction 441 of the operative force transmission member section 44 ofthe force transmission member 40. For example, where the width issubstantially uniform throughout the length of the force transmissionmember 40, the width is 19 millimetres.

(G) Second Configuration of Elongated Strap

The force transmission member 40 is also configured with other aspect(s)to facilitate air flow across the force transmission member. Forexample, this configuration also mitigates frictional losses arisingduring movement of the force transmission member 40.

In this respect, and referring to FIGS. 7, 7A, 7B, and 9, with respectto the force transmission member 40, the minimum width of at least afraction of the operative force transmission member section 44 of theforce transmission member 40 is at least 13 millimetres.

For example, the at least a fraction is at least 25% of the length ofthe operative force transmission member section 44. As a furtherexample, the at least a fraction is at least 50% of the length of theoperative force transmission member section 44.

The at least a fraction of the operative force transmission membersection 44 of the force transmission member 40 with the minimum widthco-operates with the guide system 64 during movement of the forcetransmission member 40 (in response to an application of force to theactuator 38) such that vertical movement of the operative forcetransmission member section 44 is limited during movement of the forcetransmission member 40 relative to the actuator 38. For example, withrespect to the limiting of the vertical movement of the operative forcetransmission member section 44 during movement of the force transmissionmember 40 relative to the actuator coupling unit 42, the at least afraction of the operative force transmission member section 44 of theforce transmission member 40 with the minimum width defines a clearancefor limiting vertical movement of any fraction of the operative forcetransmission member section 44 to a maximum vertical movement duringmovement of the force transmission member 40 relative to the actuatorcoupling unit 42. For example, with respect to the limiting of thevertical movement of a longitudinal axis 58 of the operative forcetransmission member section 44, the vertical movement of the axis 58 islimited to 0.635 centimetres above the axis 651 of the guide member 65and 0.635 centimetres below the axis 651.

The at least a fraction of the operative force transmission membersection 44 also includes a ratio of the operative strap surface area tolength of no less than about 13.6 mm²/mm.

For example, and referring to FIG. 9, with respect to the at least afraction of the operative force transmission member section 44 with theminimum width, the at least a fraction includes a plurality of portions84 including the minimum width, such that portions of the at least afraction alternate with narrower portions 86 (portions whose width isless than the minimum width). For example, with respect to the pluralityof portions with the minimum width, the maximum length of an operativeforce transmission member section portion with less than the minimumwidth, connecting successive portions with the minimum width, is 7.62centimetres. For example, the maximum length is 5.08 centimetres.

(H) Guard for Mitigating/Eliminating Interference by Crown to Movementof Force Transmission Member 40

Referring to FIGS. 5B and 14A, in another aspect, the actuator 38 isconfigured to effect a change in position (or movement) of the forcetransmission member 40 relative to the actuator 38 while effecting achange in the disposition of the force transmission member 40 relativeto a head 14 received within the crown 26, such that the forcetransmission member 40 moves forwardly relative to the actuator 38 whenthe actuator 38 effects application of a force to the operative forcetransmission member section 44, and the guard 88 is provided to mitigateor eliminate interference by the crown 26 to the forward movement of theforce transmission member 40 relative to the actuator 38.

In this respect, the headwear 10 is further provided with a guard 88configured for disposition between the crown 26 and the forcetransmission member 40 as the force transmission member 40 movesforwardly relative to the actuator 38 as the actuator 38 effectsapplication of a force to the operative force transmission membersection 44. For example, the guard is a thin, flexible, pliable materialwhich is fitted over a knob 1042 of the actuator 38. For example, theguard is a plastic material, such as polyurethane or polyvinylchloride.

(I) Method of Manufacturing Adjustable Headwear of a Pre-Determined Size

In another aspect, there is provided a method of manufacturingadjustable headwear 10 of a predetermined size, including a step ofconfiguring the force transmission member 40 such that the forcetransmission member 40 corresponds to the predetermined size of theheadwear 10.

In this respect, there is provided a method of manufacturing headwear 10including the crown 26 defining an opening 12 for reception of a head 14of a wearer, the actuator 38 configured for receiving an application ofa force, and a force transmission member 40 configured for dispositionrelative to a head 14 received within the crown 26. The forcetransmission member 40 is coupled to the actuator 38, such that theactuator 38 is configured to effect, relative to a head 14 receivedwithin the crown 26, a change in disposition of the force transmissionmember 40 to any one of a plurality of conditions. In at least one ofthe plurality of conditions, the force transmission member 40 is bearingagainst a surface fraction of the head 14 received within the crown 26.

Referring, in particular, to FIGS. 8 and 8A, the method includesproviding a longitudinally extending force transmission member portionpre-form 90 including a plurality of longitudinally spaced cuttingindications 92. For example, each one of the indications 92 is ascore-mark. Each one of the cutting indications 92 corresponds to apre-determined location for cutting the pre-form to provide a modifiedpre-form suitable for use as at least a portion of the forcetransmission member 40. In this respect, cutting of the pre-form at oneof the plurality of cutting indications is effected. For example, thecutting is effected by known cutting methods such as by shears,clippers, scissors, knives, bladed cutting tools, or by hot wire.

For example, the method further includes providing a crown 26 of apredetermined size, providing an actuator 38, coupling the actuator 38to the crown 26, and coupling the modified pre-form to each one of thecrown 26 and the actuator 38. For example, the modified pre-form isincorporated in a force transmission member 40, and the forcetransmission member 40 is then coupled to each one of the crown 26 andthe actuator 38.

For example, prior to coupling to each one of the crown 26 and theactuator 38, the modified pre-form is attached to the resilient member76. For example, the resilient member is stitched to the modifiedpre-form. The modified pre-form includes an attachment indicationcorresponding to a pre-determined location for attaching the resilientmember. In this respect, the resilient member is attached, such as bystitching to the modified pre-form.

In a related respect, for example, the longitudinally extending forcetransmission member pre-form also includes a plurality of longitudinallyspaced attachment indications 93. Each one of the plurality oflongitudinally spaced attachment indications 93 corresponds to and ispaired or associated with a respective one of the plurality of thecutting indications 92, such that cutting of the pre-form at one of theplurality of cutting indications 92 provides a modified pre-formincluding a free end wherein the one of the plurality of the attachmentindications 93 closest to the free end is for attachment to theresilient member 76. In this respect, the pre-form is cut at one of theplurality of cutting indications 92 to produce a modified pre-formincluding a free end. Referring to FIG. 8A, the resilient member 76 isthen attached to the one of the plurality of the attachment indications93 closest to the free end to provide a further modified pre-form. Thefurther modified pre-form is then coupled to each one of the actuator 38and the crown 26.

For example, the pre-form is an elongated strap 561. For example thestrap 561 is made from BASF A3K™ Nylon 66.

Although the disclosure describes and illustrates various embodiments ofthe invention, it is to be understood that the invention is not limitedto these particular embodiments. Many variations and modifications willnow occur to those skilled in the art of headwear. For full definitionof the scope of the invention, reference is to be made to the appendedclaims.

1.-72. (canceled)
 73. Headwear comprising: a crown defining an openingfor receiving a head of a wearer; an actuator configured for receivingan application of force, and including a force transmission membercoupling unit; a force transmission member coupling portion; and a forcetransmission member including an operative force transmission membersection, wherein the operative force transmission member sectionincludes an actuator coupling portion and a crown coupling portion, andwherein the actuator coupling portion is coupled to the forcetransmission coupling unit of the actuator, and wherein the crowncoupling portion is coupled to the force transmission member couplingportion, and wherein the force transmission member includes a relativelyharder portion and a relatively softer portion; such that, the actuatoris configured to effect, when a head is received within the crown, anapplication of a force to the operative force transmission membersection, such that the operative force transmission member sectionchanges its condition relative to a surface fraction of the headreceived within the crown to any one of a plurality of conditions inresponse to an application of force to the actuator, wherein, in atleast one of the plurality of conditions, an operative surface of theoperative force transmission member section is bearing against a surfacefraction of the head received within the crown.
 74. The headwear asclaimed in claim 73, wherein the force transmission member is a strap.75. The headwear as claimed in claim 73, wherein the force transmissionmember includes a strap.
 76. The headwear as claimed in claim 73,wherein the crown includes the force transmission member couplingportion.
 77. The headwear as claimed in claim 76, wherein the forcetransmission member includes a strap.
 78. The headwear as claimed inclaim 76, wherein the force transmission member is attached to the forcetransmission member coupling portion.
 79. The headwear as claimed inclaim 73, wherein the relatively softer portion includes a resilientportion, and the resilient portion is at least about 5.5% of the lengthof the operative force transmission member section.
 80. The headwear asclaimed in claim 79, wherein the resilient portion is less than about18.5% of the length of the operative force transmission member section.81. The headwear as claimed in claim 73, wherein the length of therelatively harder portion is less than about 33% of the length of theoperative force transmission member section.
 82. The headwear as claimedin claim 73, wherein the relatively harder portion is a plastic.
 83. Theheadwear as claimed in claim 80, wherein the relatively harder portionis a plastic.
 84. The headwear as claimed in claim 83, wherein therelatively softer portion also includes a substantially inelastic strapportion.
 85. The headwear as claimed in claim 80, wherein the length ofthe relatively harder portion is less than about 33% of the length ofthe operative force transmission member section.
 86. The headwear asclaimed in claim 81, wherein the relatively harder portion is a plastic.